Bluegrass Companies

Last updated
Bluegrass Companies
Type Private
IndustryNon-Explosive Demolition
Engineering
Founded1979;44 years ago (1979)
HeadquartersGreenville, AL
(Headquarters)
Broussard, LA
(Registered office)
Houston, TX
(Registered office)
Hanford, WA
(Registered office)
Dubois, WY
(Registered office)
Area served
Worldwide
Key people
Nicholas Jenkins (CEO and Owner)
ServicesDiamond wire sawing, Concrete shaving, Robotic hammering, Expansive-grout supplier
Number of employees
50+ (August 2015)
Website Bluegrassbit.com

Bluegrass Companies is a non-explosive demolition company headquartered in Greenville, Alabama. It was founded in 1979 by CEO and owner Nicholas Jenkins. [1] The business comprises the sub-companies: Demolition Technologies, The Machine Shop, Bluegrass Concrete Cutting Inc., and Bluegrassbit. Bluegrass Company has always been headquartered in Greenville, Alabama, though now incorporated in Wyoming. [2] The company is known for the advancement of diamond wire sawing as a technique for non-explosive demolition, later for the creation and patenting of an underwater diamond wire saw, [3] and for assisting the U.S. Department of Energy with various tests [4] as well as nuclear decommissioning. [5]

Contents

Nuclear

Power plant decommissioning

Bluegrass has performed reactor vessel cutting and steam generator replacements at Sequoyah, Watts Bar, Browns Ferry, Waterford Nuclear Generating Station, Connecticut Yankee, Humboldt Bay, and Big Rock Point Nuclear power plants over the course of the last 30 years. [6]

Plutonium Immobilization Project

The company has worked for the government of the United States of America: Department of energy on their Plutonium Immobilization Project, "After the low pour rate and instrumented canisters cooled, Bluegrass Bit, Inc. used a diamond wire saw to section them at four heights. The sections were then studied for evidence of hardware deformation and glass voids." [4] This project focused on the finding a way to disposition excess plutonium of a weapons grade classification.

Diamond shaving of contaminated concrete surfaces

The company helped to test using diamond shaving to decontaminate radioactive surfaces. [7]

Tokamak Fusion Test Reactor (TFTR)

In 1997, Bluegrass with the help of the Princeton Physics Laboratory offered a demonstration of how the TFTR could be disassembled with diamond wire sawing, "Based upon the demonstration at PPPL on the TFTR surrogate, the diamond wire cutting technology is superior to the baseline technology for both cost and safety considerations. The combination of void filling with this cutting technology will significantly reduce personnel radiation exposure through shielding, remote operation (normal application of this technology), and radionuclide stabilization". [8] [9]

ITER

In 2018, Bluegrass supported General Atomics by cutting a 14 scale mockup of the ITER [10] solenoid constructed by wrapping 288 individual stainless steel bars with copper conductor and coiling the resulting "superconductor" into a ring 3 ft tall x 2 12 ft wide. The heart of the ITER tokamak, a solenoid is used to magnetically confine a plasma of reactive charged particles into a hollow doughnut-shaped container. The ring of stainless steel and copper was segmented into 4 pieces sized for shipment to another facility for analysis.

NS Savannah

Retired NS (Nuclear Ship) Savannah, [11] anchored at Baltimore, MD, underwent a renovation in 2018 which required cutting into the nuclear containment vessel to gain access to the reactor. Bluegrass engineered and fabricated bespoke equipment for the confined space to cut, lift and move the 2 ton containment wall cut blocks. The removal of the cut segments had to all be done in a very confined space mostly by manual labor and an elaborate pulley system designed specifically for this job alone.

Civil

Transportation: highways, railroads, ports, bridges

Railway bridge projects include a Union Pacific Railroad over the Willamette River in Oregon, and a BNSF pivot bridge over Bayou des Allemandes. Highway bridge projects include the Dumbarton Bridge in California and Wisner Boulevard bridge [12] in New Orleans, LA. At the Port of Los Angeles, CA, an underwater wire saw cut Berth 29 for removal. On the demolition of the East Span of the San Francisco-Oakland Bay Bridge [13] in Spring 2017, Bluegrass cut and segmented the above-water blocks of Piers E6, E7, E8, and E10 through E16, then core drilled for rigging and removal all the cut blocks except those on E6. The pier demolition project was authorized by the San Francisco Bay Conservation and Development Commission [14] in part to mitigate for all the fill associated with construction of the new East Span of the Bay Bridge.

Hydroelectric

Bluegrass Slot Cut at Hiwassee Dam HiwasseeDamSlotCut.jpg
Bluegrass Slot Cut at Hiwassee Dam

Projects such as Hiwassee Dam [15] and Fontana Dam [16] have been a focus of the company as well, also see their work with Tennessee Valley Authority. [17] With regard to dam remediation and upgrades, slot cutting projects are the company's main focus. It is akin to slicing a concrete dam like a piece of birthday cake. The technique is simple but very difficult, rotate a loop of cable strung with diamond embedded beads through the structure — essentially, like using a loop of fishing line to cut a cake. Slot cutting is employed to create expansion joints in dams afflicted with compression stresses due to concrete swelling. Alkali Aggregate Reaction, or AAR, is a chemical reaction in concrete created where the aggregate has a high silicon dioxide content. The southeast USA is one such region, and dams in that area require periodic slot cuts to avoid cracking, leakage, and interference with mechanical components such as gates and turbines. The time intervals depend on the AAR specifics of each structure, but 10 years is an average.

Bluegrass participated in the Saluda Dam Remediation project in South Carolina, a requirement by the Federal Energy Regulatory Commission which involved seismic upgrades to the dam and building a backup dam immediately downstream. Bluegrass was contracted to assist with removal of concrete piers and retaining wall to provide access to the penstock towers which supply water to the turbines in the hydroelectric plant. Bluegrass diamond wire saws were ideally suited to the job because of the minimal vibration emitted, therefore avoided the potential hazard of vibrating debris into the draft tubes. Expansive grout and robotic hammers were also used to break the concrete blocks for removal.

NASA

Cell B&C are demolished to make room for new SLS tooling. Nasa c cell demolition bluegrass.jpg
Cell B&C are demolished to make room for new SLS tooling.

As part of planning the Orion programme for the journey beyond low Earth orbit to destinations such as Mars, NASA needed to demolish the existing concrete silos (built to assemble the Space Shuttle booster rockets) at their Michoud Assembly Facility. This was necessary in order to replace the silos with larger Space Launch System (SLS) core stage assembly towers. The task of removing the existing concrete silos was estimated to take three months. Bluegrass was called in to regain schedule for the overall project, eventually completing the demolition of cells B and C in a month. [18] [19]

Offshore

In 2006, Bluegrass created an underwater saw and had it patented for its use of hydraulic motors in combination with diamond wire to create a new sawing platform which was operational underwater. The continuous loop, four wheel drive diamond wire saw reduced cut times by providing greater torque and consistent wire grip. These improvements reduced slippage and subsequent wire breaks. Since then the patented underwater saw has been used domestically and globally on offshore decommissioning jobs including cutting single- and multi-string conductors, pipelines, seabed umbilicals, pilings, mooring chains, wellheads, risers, slot recovery and jacket lets. On platforms this technology can be applied to perform modifications, maintenance upgrades, to remove crane pedestals, compressors and topsides, and for hurricane remediation. Sub-sea saws can be installed by divers while being monitored and powered from a barge or platform, or they can be installed and powered by working class ROVs. The robust characteristics of these four wheel drive bespoke underwater wire saws, combined with remote control functionality, makes them suitable to extreme offshore decommissioning conditions such as the North Sea.

U.S. Patent #8,286,625

Bluegrass Underwater Saw Under-water-saw-bluegrass.jpg
Bluegrass Underwater Saw

The patent [3] was filed with the advantages being summarized as follows:

  1. An advantage of the present invention is a diamond wire saw assembly that provides the ability to cut large diameter heavy walled multi-string pipes remotely, safely and quickly.
  2. Another advantage is a diamond wire saw assembly that eliminates labor-intensive methods requiring the use of divers at extreme depths.
  3. Another advantage is that the diamond wire saw assembly can be deployed by remotely operated vehicles.
  4. Another advantage is that the diamond wire saw assembly can be used for removal of damaged offshore oil platforms as well as for decommissioning of oil platforms that have reached their useful life and are being removed.
  5. Another advantage is a diamond wire saw assembly that is portable.
  6. Another advantage is a diamond wire saw that eliminates wire breakage.

Hurricane remediation

Bluegrass was involved in the arduous post-Katrina and -Rita cleanup of toppled or damaged offshore production platforms. Operating from work vessels chartered by Chevron, the cleanup team moved from platform to platform in the Gulf of Mexico, cutting structural platform members, stringers and caissons underwater and on deck to comply with BOEM and BSEE federal requirements to remove O & G (Oil and Gas) production debris from the seafloor.

Industrial

Examples of application to heavy industry include foundation removals and modifications, chest removals in the pulp and paper industry, brick and refractory removal primarily using robotic hammers, and boiler segmentation. In many industrial plants such as cememt, lime, copper, aluminum, and chemical, the kiln's refractory lining wears out and needs to be replaced, or is compromised by lime buildup which must be removed. For these demolition jobs, remotely operated robotic hammers are used to break up the refractory for removal, and for chipping off lime deposits.

Paper mills

The production of wood pulp and paper products requires extensive concrete structures including foundations, walls, raised platforms and kilns. Refractory in kilns needs to be replaced periodically. A variety of maintenance, upgrade, retrofit, and replacement projects in this industry calls into service the full array of demolition equipment: core drills and diamond wire saws for cutting concrete bases, walls and foundations, and for releasing and cutting tanks and chests. Robotic hammers are able to work in the limited space of kilns to effectively break refractory and lime buildup for removal.

Chemical plants and refineries

The structures, mechanisms and environments of chemical plants and refineries are ideal candidates for the spark-free and vibration-free concrete and metal cutting technologies used by Bluegrass.

Heavy metal

Los Alamost National Laboratories (LANL) Technical Area 54 contracted Bluegrass for assistance with a stockpile cleanup project. [20] The inventory of 84" diameter exotic steel spheres needed to be segmented into sizes suitable for containment and disposal. Bluegrass designed a saw to these specifications: it had to make a continuous cut, without stopping, through steel nearly 3" thick, and to avoid creating contaminated slurry it could not be cooled with water, typically wire saws are cooled by water, thus the wire burned out quicker.

Related Research Articles

A saw is a tool consisting of a tough blade, wire, or chain with a hard toothed edge used to cut through material. Various terms are used to describe toothed and abrasive saws.

<span class="mw-page-title-main">Chainsaw</span> Portable handheld powered cutting tool

A chainsaw is a saw that cuts with a set of teeth attached to a rotating chain driven along a guide bar. Modern chainsaws are used in activities such as tree felling, limbing, bucking, pruning, cutting firebreaks in wildland fire suppression, harvesting of firewood, for use in chainsaw art and chainsaw mills, for cutting concrete, and cutting ice. Precursors to modern chainsaws were first used in surgery, with patents for wood chainsaws beginning in the late 19th century.

<span class="mw-page-title-main">Tunnel boring machine</span> Device used to excavate tunnels

A tunnel boring machine (TBM), also known as a "mole", is a machine used to excavate tunnels. Tunnels are excavated through hard rock, wet or dry soil, or sand, each of which requires specialized technology.

<span class="mw-page-title-main">Prestressed concrete</span> Form of concrete used in construction

Prestressed concrete is a form of concrete used in construction. It is substantially "prestressed" (compressed) during production, in a manner that strengthens it against tensile forces which will exist when in service.

<span class="mw-page-title-main">Zion Nuclear Power Station</span> Decommissioned nuclear power plant in Lake County, Illinois

Zion Nuclear Power Station was the third dual-reactor nuclear power plant in the Commonwealth Edison (ComEd) network and served Chicago and the northern quarter of Illinois. The plant was built in 1973, and the first unit started producing power in December 1973. The second unit came online in September 1974. This power generating station is located on 257 acres (104 ha) of Lake Michigan shoreline, in the city of Zion, Lake County, Illinois. It is approximately 40 direct-line miles north of Chicago, Illinois and 42 miles (68 km) south of Milwaukee, Wisconsin.

Underwater demolition is the deliberate destruction or neutralization of man-made or natural underwater obstacles, both for military and civilian purposes.

<span class="mw-page-title-main">Trojan Nuclear Power Plant</span> Nuclear power plant in Oregon, US

Trojan Nuclear Power Plant was a pressurized water reactor nuclear power plant in the northwest United States, located southeast of Rainier, Oregon, and the only commercial nuclear power plant to be built in Oregon. There was much public opposition to the plant from the design stage. The three main opposition groups were the Trojan Decommissioning Alliance, Forelaws on the Board, and Mothers for Peace. There were largely non-violent protests from 1977, and subsequent arrests of participants.

<span class="mw-page-title-main">Bull Run Hydroelectric Project</span> Dam in Oregon

The Bull Run Hydroelectric Project was a Portland General Electric (PGE) development in the Sandy River basin in the U.S. state of Oregon. Originally built between 1908 and 1912 near the town of Bull Run, it supplied hydroelectric power for the Portland area for nearly a century, until it was removed in 2007 and 2008. The project used a system of canals, tunnels, wood box flumes and diversion dams to feed a remote storage reservoir and powerhouse. The entire project was removed because of rising environmental costs. Marmot Dam on the Sandy River was demolished in 2007, and the Little Sandy Dam on the Little Sandy River was taken down in 2008.

<span class="mw-page-title-main">Dowel bar retrofit</span> Highway crack treatment

A dowel bar retrofit (DBR) is a method of reinforcing cracks in highway pavement by inserting steel dowel bars in slots cut across the cracks. It is a technique which several U.S. states' departments of transportation have successfully used in repairs to address faulting in older jointed plain concrete pavements. The typical approach is to saw cut and jackhammer out the slots for the dowels. Following dowel placement the slots are then typically backfilled with a non-shrink concrete mixture, and the pavement is diamond-ground to restore smoothness.

<span class="mw-page-title-main">Chernobyl New Safe Confinement</span> Protective building over nuclear reactor

The New Safe Confinement is a structure put in place in 2016 to confine the remains of the number 4 reactor unit at the Chernobyl Nuclear Power Plant, in Ukraine, which was destroyed during the Chernobyl disaster in 1986. The structure also encloses the temporary Shelter Structure (sarcophagus) that was built around the reactor immediately after the disaster. The New Safe Confinement is designed to prevent the release of radioactive contaminants, protect the reactor from external influence, facilitate the disassembly and decommissioning of the reactor, and prevent water intrusion.

<span class="mw-page-title-main">Hole saw</span> Cylindrical saw used to quickly cut holes

A hole saw, also known as a hole cutter, is a saw blade of annular (ring) shape, whose annular kerf creates a hole in the workpiece without having to cut up the core material. It is used in a drill. Hole saws typically have a pilot drill bit (arbor) at their center to keep the saw teeth from walking. The fact that a hole saw creates the hole without needing to cut up the core often makes it preferable to twist drills or spade drills for relatively large holes (especially those larger than 25 millimetres. The same hole can be made faster and using less power.

<span class="mw-page-title-main">Wire saw</span> Saw that uses abrasive metal wire or cable

A wire saw is a saw that uses a metal wire or cable for mechanical cutting of bulk solid material such as stone, wood, glass, ferrites, concrete, metals, crystals etc.. Industrial wire saws are usually powered. There are also hand-powered survivalist wire saws suitable for cutting tree branches. Wire saws are classified as continuous or oscillating. Sometimes the wire itself is referred to as a "blade".

<span class="mw-page-title-main">Diamond tool</span>

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<span class="mw-page-title-main">Diamond blade</span> Saw blade with diamond grit bonded to the cutting surface

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<span class="mw-page-title-main">Hydrodemolition</span> High-pressure water jet used to remove degraded concrete

Hydrodemolition is a concrete removal technique which utilizes high-pressure water, often containing an abrasive material, to remove deteriorated and sound concrete as well as asphalt and grout. This process provides an excellent bonding surface for repair material and new coating applications. First developed in Europe in the 1980s, this technology has become widely accepted for concrete removal and surface preparation throughout Europe and North America.

Nuclear entombment is a method of nuclear decommissioning in which radioactive contaminants are encased in a structurally long-lived material, such as concrete. This prevents radioactive material and other contaminated substances from being exposed to human activity and the environment. Entombment is usually applied to nuclear reactors, but also some nuclear test sites. Nuclear entombment is the least used of three methods for decommissioning nuclear power plants, the others being dismantling and deferred dismantling. The use of nuclear entombment is more practical for larger nuclear power plants that are in need of both long and short term burials, as well as for power plants which seek to terminate their facility licenses. Entombment is used on a case by case basis because of its major commitment with years of surveillance and complexity until the radioactivity is no longer a major concern, permitting decommissioning and ultimate unrestricted release of the property. Considerations such as financial backing and the availability of technical know-how are also major factors.

Diamond grinding is a pavement preservation technique that corrects a variety of surface imperfections on both concrete and asphalt concrete pavements. Most often utilized on concrete pavement, diamond grinding is typically performed in conjunction with other concrete pavement preservation (CPP) techniques such as road slab stabilization, full- and partial-depth repair, dowel bar retrofit, cross stitching longitudinal cracks or joints and joint and crack resealing. Diamond grinding restores rideability by removing surface irregularities caused during construction or through repeated traffic loading over time. The immediate effect of diamond grinding is a significant improvement in the smoothness of a pavement. Another important effect of diamond grinding is the considerable increase in surface macrotexture and consequent improvement in skid resistance, noise reduction and safety.

<span class="mw-page-title-main">The Castle Group</span>

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